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DEIF A/S Frisenborgvej 33 DK-7800 Skive Tel.: +45 9614 9614 Fax: +45 9614 9615 info@deif.com www.deif.com
isenborgvej 33 DK-7800 Skive Tel.: +45 9614 9614 Fax: +45 9614 9615 info@deif.com www.deif.com Document no.: 4189340752C
14 9614 Fax: +45 9614 9615 info@deif.com www.deif.com SW version: 4.0x.x
AGC 100 installation instructions
4189340752 UK
1. General information
1.1. Warnings, legal information and safety..................................................................................................3
1.1.1. Warnings and notes ......................................................................................................................3
1.1.2. Legal information and disclaimer ..................................................................................................3
1.1.3. Safety issues ................................................................................................................................3
1.1.4. Electrostatic discharge awareness ...............................................................................................3
1.1.5. Factory settings ............................................................................................................................3
1.1.6. UL applications..............................................................................................................................4
1.2. About the installation instructions...........................................................................................................4
1.2.1. General purpose ...........................................................................................................................4
1.2.2. Intended users ..............................................................................................................................4
1.2.3. Contents and overall structure ......................................................................................................4
2. Mounting
2.1. AGC 100 mounting.................................................................................................................................5
2.1.1. Unit dimensions and panel cutout..................................................................................................5
2.1.2. Tightening torques.........................................................................................................................6
3. Terminals
3.1. Terminal overview and description.........................................................................................................7
3.1.1. Terminal description......................................................................................................................7
4. Wiring
4.1. Wiring diagram.....................................................................................................................................11
4.2. DC connections....................................................................................................................................12
4.3. Digital inputs.........................................................................................................................................13
4.4. Breaker selection..................................................................................................................................13
4.5. Charger alternator connections............................................................................................................14
4.6. 3-phase voltage and current wiring......................................................................................................16
4.6.1. 3-phase wiring, AGC 112.............................................................................................................16
4.6.2. 3-phase AMF wiring, AGC 113....................................................................................................17
4.7. 1-phase voltage and current wiring......................................................................................................18
4.8. Split-phase voltage and current wiring.................................................................................................19
4.9. Power management 3-phase wiring (AGC 145/146)............................................................................20
4.9.1. Mains breaker, AGC 145 ............................................................................................................20
4.9.2. Mains and tie breaker, AGC 146 ................................................................................................21
5. Communication
5.1. Wiring instructions................................................................................................................................22
5.2. Modbus RTU........................................................................................................................................23
5.2.1. Connection with 2-wire shielded cable (recommended)..............................................................23
5.2.2. Connection with 3-wire shielded cable........................................................................................24
5.3. CAN bus engine communication..........................................................................................................25
5.3.1. Connection with 2-wire shielded cable (recommended)..............................................................25
5.3.2. Connection with 3-wire shielded cable........................................................................................26
5.4. External I/O modules............................................................................................................................27
5.5. Additional Operator Panel, AOP-2.......................................................................................................28
1. General information
1.1 Warnings, legal information and safety
1.1.1 Warnings and notes
Throughout this document, a number of warnings and notes with helpful user information will be presented.
To ensure that these are noticed, they will be highlighted as follows in order to separate them from the gener-
al text.
Warnings
Warnings indicate a potentially dangerous situation, which could result in death, personal in-
jury or damaged equipment, if certain guidelines are not followed.
Notes
Notes provide general information, which will be helpful for the reader to bear in mind.
The Multi-line 2 unit is not to be opened by unauthorised personnel. If opened anyway, the war-
ranty will be lost.
Disclaimer
DEIF A/S reserves the right to change any of the contents of this document without prior notice.
Be aware of the hazardous live currents and voltages. Do not touch any AC measurement in-
puts as this could lead to injury or death.
1.1.6 UL applications
These flat surface panel-mounted controllers are intended to be used in Listed Generator Assemblies, where
the suitability of the combination has been determined by Underwriters Laboratories.
The general purpose of this document is to give the user important information to be used in the installation of
the unit.
Please make sure to read this document before starting to work with the Multi-line 2 unit and
the gen-set to be controlled. Failure to do this could result in human injury or damage to the
equipment.
2. Mounting
2.1 AGC 100 mounting
The unit is designed for flush mounting by means of eight fixing clamps (IP52), which are included at delivery.
To have IP65, the unit must be ordered with option L (12 fixing clamps and a gasket).
In order to ensure optimum mounting, the panel door must be cut out according to the following measure-
ments:
220.0 (8.66)
Alarm 1 0.3 Nm
Alarm 2
Alarm 3
Alarm 4
160.0 (6.30)
151.0 (5.94)
211.0 (8.30)
54.0 (2.13)
61.0 (2.40)
Unit panel door mounting: 0.3 Nm, 2.7 lb-in (see diagram in "Unit dimensions and panel cutout")
Plug connections (terminals): 0.5 Nm, 4.4 lb-in
220.0 (8.661)
0.2 Nm
115.0 (4.528)
Display
9P Female
Sub 0
connector
0.7 Nm
Screw M3
Bossard BN5687 Max. 10 mm
or similar Min. 6 mm
20.0 (0.787)
3. Terminals
3.1 Terminal overview and description
Unit rear view
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
+ -
Com
Com
MPU
Com
W/L
Com
Power
Emergency stop
Status Multi-functional
R21
R22
R23
supply inputs Binary inputs RPM inputs R24 R26
B(-) 49
RS485
Modbus GND 50
A(+) 51
52
CAN H 53
The RJ11 connector for the PC connection interface box is placed on the side of the unit.
23 Relay output
24-25 Relay output Configurable. Function NO. Contact ratings 8 A 30 V DC/V
26-27 Relay output AC
* The status relay is the uP watchdog output. This relay is normally energised, and the switch is closed after
power-up. If the uP fails or the power is lost, the relay will de-energise and the switch will open. If the unit fails
to start up at power-up, then the relay switch will remain open. The relay is configurable.
** If terminal 20 is used for emergency stop, please see wiring diagram below.
The relay output functions are configurable via the PC utility software and can, among many other functions,
be configured to cover the following in I/O settings:
Status OK
Run coil
Stop coil
Stop coil (not activated in start seq.)
Prepare
Starter(crank)
Horn
GB on
GB off
MB on
MB off
It is possible to choose run coil on one relay and stop coil on another, thus supporting engines with double
systems.
Tacho RPM input (MPU) can be configured to cover the following functions:
Tacho RPM input with capacitor (W/L) can be configured to cover the following functions:
The generator voltage and current input can be configured to the following:
4. Wiring
4.1 Wiring diagram
Charging Controller
alternator
D- D+ Running
12
1N4007 Programming
tool
Rex
27 R26
Alarm RJ11
26
plug
25 R24
Alarm horn Oli pressure
24 15
RUN coil Coolant temp.
23 R23 14
Starter Overspeed
22 13
R22
Start prep.
21
R21
Emer. STOP Remote start
20 11
Start enable
19 10
4 9
Status
3
F
- + - +
1
Battery
2
Rex: 12 V systems: 47 4 W
24 V systems: 100 6 W
If a stop coil is used, the REX resistor can be connected to the starter relay (crank).
The illustrated configuration is an example of settings. The use of the relays can be chosen
freely.
It is important to protect the unit against damage caused by high voltages. Therefore, the fuse
must not be more than 2 A slow-blow.
4.2 DC connections
* The illustration for the RMI sensors also apply to Pt1000 - but note that only multi-inputs 6 and 7 support
Pt1000.
+12/24V DC
Bin IN
Common
0V DC
The digital inputs use fixed signals. Only the mode shift input and the test input (if the timer is
used) use pulse signal.
In the table below it is listed which outputs are needed for breaker handling, depending on the breaker type.
If the AGC 100 is ordered with option M19, relay 47 will have NO contact.
Running
feedback
Run coil RPM
input
9 24 25 12 18 17
Rex
Battery
- +
1N4007
B+ D+ W
Brush
U V W
Charger Exciter
alternator coil (rotor)
Brush
Stator
Excitation
controller
At standstill, the battery + is connected to terminal 9 (common), and a current flows to terminal 12 and via the
D+ input on the alternator to ground (battery -). When the starter is engaged (cranking), the battery will supply
the D+ through the REX resistor, helping the alternator to excite. When the alternator starts to produce volt-
age (excitation OK), the speed of the alternator will be above running speed, and the voltage on term. 12 will
rise to a value higher than the battery voltage and then interrupt the current flow through REX and activate
the running feedback input. Engine is running.
If a stop coil is used, the REX resistor can be connected to the starter relay (crank).
Consumer
N L1 L2 L3
Supply
45 GB ON
46 command
GB
14 GB OFF feedback
33 UL1
36 UL2 GENERATOR
34 N VOLTAGE
38 UL3
s2
40
I1
39
s1
s2
42
I2 GENERATOR
41 CURRENT
s1
s2
44
I3
43
s1
GENERATOR
MAINS
N L1 L2 L3
28 UL1
29 N MAINS
30 UL2 VOLTAGE
32 UL3
Supply
15 MB OFF feedback
MB
47 MB ON
48 command
Consumers 45 GB ON
46 command
GB
14 GB OFF feedback
33 UL1
36 UL2 GENERATOR
34 N VOLTAGE
38 UL3
s2
40
I1
39
s1
s2
42
I2 GENERATOR
41 CURRENT
s1
s2
44
I3
43
s1
GENERATOR
28 UL1
MAINS
29 N VOLTAGE
Supply
45 GB ON
46 command 15 MB OFF feedback
MB
GB 47 MB ON
14 GB OFF feedback 48 command
Consumers
45 GB ON
46 command
33 UL1
GENERATOR GB
34 N VOLTAGE
14 GB OFF feedback
s2
40 GENERATOR
I1 33 UL1
39 CURRENT
s1 GENERATOR
34 N
VOLTAGE
GENERATOR s2
40
I1 GENERATOR
39 CURRENT
s1
GENERATOR
Supply 28 UL1
29 N MAINS
30 UL2 VOLTAGE
Supply
45 GB ON
15 MB OFF feedback
46 command
MB
47 MB ON
GB
48 command
14 GB OFF feedback Consumers
45 GB ON
46 command
33 UL1
GB
36 UL2 GENERATOR
VOLTAGE 14 GB OFF feedback
34 N
s2 33 UL1
40
I1
39 36 UL2 GENERATOR
s1
s2 34 N VOLTAGE
42
I2 GENERATOR
41 CURRENT
s1
s2
40
I1
39
s1
s2
42
I2 GENERATOR
41 CURRENT
s1
GENERATOR
GENERATOR
BUSBAR
N L1 L2 L3
28 UL1
29 N BUSBAR
30 UL2 VOLTAGE
32 UL3
Supply
Consumers 45 MB ON
46 command
MB
14 MB OFF feedback
33 UL1
34 N MAINS
36 UL2 VOLTAGE
38 UL3
s2
40
I1
39
s1
s2
42 MAINS
I2
41 CURRENT
s1
s2
44
I3
43
s1
N L1 L2 L3
MAINS
BUSBAR
N L1 L2 L3
28 UL1
29 N BUSBAR
30 UL2 VOLTAGE
32 UL3
Supply
15 TB OFF feedback
TB
47 TB ON
48 command
Consumers 45 MB ON
46 command
MB
14 MB OFF feedback
33 UL1
34 N MAINS
36 UL2 VOLTAGE
38 UL3
s2
40
I1
39
s1
s2
42 MAINS
I2
41 CURRENT
s1
s2
44
I3
43
s1
N L1 L2 L3
MAINS
5. Communication
5.1 Wiring instructions
Cable
Belden 3106 A or equivalent. 22 AWG (0.324 mm2) shielded twisted pair, min. 95 % shield coverage.
Cable shield
Connect the cable shield to earth at one end only.
Never connect the GND terminal to earth directly or through the shield!
If the GND terminal is connected to a PLC or other device, the GND connection of this device
must be isolated from earth!
DATA (GND)
DATA - (B)
DATA + (A)
DATA (GND)
DATA - (B)
DATA + (A)
DATA (GND)
DATA - (B)
29 30 31 29 30 31 29 30 31
DATA - (B)
DATA (GND)
DATA + (A)
DATA (GND)
DATA - (B)
DATA + (A)
DATA (GND)
DATA - (B)
DATA + (A)
DATA (GND)
DATA - (B)
29 30 31 29 30 31 29 30 31
DATA - (B)
DATA (GND)
DATA + (A)
In case of very long lines on the network, terminating resistors might be needed (typically 120
1 %, 0.5 W).
Multi-line 2
CAN-H
Com
CAN-L
53 54 55
R
CAN-L
Com
CAN-H
ECM
engine control module
Multi-line 2
CAN-H
Com
CAN-L
53 54 55
R
CAN-L
Com
CAN-H
ECM
engine control module
AGC 100
Option H8
120
120
CAN-H
57
58
CAN-L
59
I/O RUN
I/O EER
BECKHOFF
ON
1 2 3 4 5 6 7 8
If external I/O modules "Option H8" are used together with AOP-2, the total terminal resistance
of the AOP-2 and the external I/O controller must be 120 .
App./Bootl.
End res.
CAN L CAN H
57 OFF CAN 1 CAN 2
59
ON
R=120
Black/white
Brown/white
Brown/white
Black/white
Red/white
Red/white
Black
Brown
Black
Red
Red
-+
5V DC
Terminal block DIN rail
24V DC
1 2
Common
NO
NC
-+
Comm. to
Cable shield next units
Status relay
1...6 1...6
If external I/O modules "Option H8" are used together with AOP-2, the total end resistance of
the AOP-2 and the external I/O controller must be 120 .
A DC/DC converter for the DC supply voltage and 2 1 m cable with an RJ12 plug in one end
and stripped wires in the other end are included in the AOP-2 delivery.